Stackable insulated unit for wall construction and method

ABSTRACT

A stackable insulated unit for wall construction for cooperation with conventional wall studs forming a self-supporting wall structure consists of two side wooden planks spaced apart and provided therebetween with an insulating layer which has at least two transverse through openings for reception of respective wall stud sections, either slidably or permanently secured thereto.

CROSS REFERENCE TO RELATED APPLICATIONS

Benefit of U.S. Provisional Applications for Patent Ser. No. 60/700,723, filed on Jul. 20, 2005, and Ser. No. 60/733,171, filed on Nov. 4, 2005, is hereby claimed.

FIELD OF THE INVENTION

The present invention relates to a wall building construction unit and methods and is more particularly concerned with a prefabricated insulated and stackable element.

BACKGROUND OF THE INVENTION

It is well known in the art to build wooden frameworks for housing walls. An insulating core is then usually inserted in-between the studs and lintels or headers and closed with facing panels. This standard operation can be time consuming and have considerable effects in areas where the residential building period is constrained to a few months of the year due to for example a harsh winter climate.

Numerous construction elements have been proposed for wall construction such as in the following documents:

-   -   U.S. Pat. No. 2,902,733 granted to Justus on Sep. 8, 1959 for a         “Corner Construction for Sawed Timber Walls”;     -   U.S. Pat. No. 3,552,079 granted to Mortensen on Jan. 5, 1971 for         a “Laminated Tongue and Groove Building Element”;     -   U.S. Pat. No. 3,742,665 granted to Henry et al. on Jul. 3, 1973         for a “Modular Building Construction”;     -   U.S. Pat. No. 4,344,263 granted to Farmont on Aug. 17, 1982 for         a Building Log with High Thermal Insulation Characteristics”;     -   U.S. Pat. No. 4,503,648 granted to Mahaffey on Mar. 12, 1985 for         a “Lightweight Composite Building Module”;     -   U.S. Pat. No. 4,614,071 granted to Sams et al. on Sep. 30, 1986         for “Building Blocks”;     -   U.S. Pat. No. 4,937,122 granted to Talbert on Jun. 26, 1990 for         an “Insulated Construction Element”; and     -   U.S. Pat. No. 6,000,177 granted to Davidson on Dec. 14, 1999 for         a “Building Structure Having the Appearance of a Log Structure”.

All the above lack either a provision for an insulated section in the stacking panel; a prefabricated insulated element; or passageways for a conventional approved wooden stud, approved and even required by most territorial or state building codes, forming a self-supporting wall structure, especially for external walls (thereby putting the load-bearing constraints on the stacking wall sections which is not regulated or preferred in building construction).

Accordingly, there is a need for an improved log, member or unit for wall construction with a simple configuration.

SUMMARY OF THE INVENTION

It is therefore a general object of the present invention to provide an improved unit for wall construction.

An advantage of the present invention is that the unit for wall construction is insulated and can be easily mounted on a stud structure which provides the structural support approved for load-bearings under construction codes.

Another advantage of the present invention is that the unit for wall construction is prefabricated at another location than the wall construction site.

A further advantage of the present invention is that the units for wall construction being relatively lightweight, can be quickly stacked on one another.

Yet another advantage of the present invention is that the unit for wall construction enables fast construction of rigid insulated walls which can eventually be disassembled and reassembled at another location.

Still another advantage of the present invention is that the unit for wall construction provides for sidewalls which naturally oppose warping when each of said sidewalls is made of multiple wood members.

Another advantage of the present invention is that the unit for wall construction includes stud longitudinal sections extending into through openings and secured to the unit, the stud longitudinal sections being used to support the structural transversal, typically vertical, loads transmitted through the wall structure.

A further advantage of the present invention is that the unit for wall construction has wall studs extending there through that are spaced from the side wooden planks for increased insulation between the two side planks.

According to an aspect of the present invention, there is provided a stackable unit for wall construction for cooperation with wall stud members forming a self-supporting wall structure, the unit comprising: first and second opposed elongate side wooden planks secured to one another with an insulating layer bonded thereto, the insulating layer having a plurality of through openings spaced from one another and extending transversely therethrough for receiving a longitudinal section of respective said stud member.

In one embodiment, respective said stud longitudinal section is permanently secured to the unit when inserted into corresponding said through opening, each said stud longitudinal section being adapted to structurally connect to at least one corresponding said stud longitudinal section of an adjacent said unit via a securing member for forming the self-supporting wall structure and having structural loads transmitted therethrough.

Typically, each said stud longitudinal section is adapted to be in abutting engagement with and securable to at least one corresponding said stud longitudinal section of an adjacent said unit.

Conveniently, each said stud longitudinal section has a through hole extending longitudinally therealong for slidably receiving the securing member therethrough for connection with said at least one corresponding said stud longitudinal section of an adjacent said unit.

Conveniently, each said securing member forces corresponding said stud longitudinal section to be in abutting engagement with said at least one corresponding said stud longitudinal section of an adjacent said unit.

Conveniently, the securing member is a screw-nut fastener for clamping corresponding said stud longitudinal section in abutting engagement with said at least one corresponding said stud longitudinal section of an adjacent said unit. Conveniently, each said securing member is a screw screwably extending through corresponding said stud longitudinal section and screwing into said at least one corresponding said stud longitudinal section of an adjacent said unit to be in secured abutting engagement therewith.

Alternatively, each said stud longitudinal section has a protrusion member extending longitudinally outwardly from a first end thereof and a cavity member extending longitudinally inwardly into an opposed second end thereof, said protrusion member being adapted to engage corresponding said cavity member of a stud longitudinal section of a first adjacent said unit, and said cavity member being adapted to receive corresponding said protrusion member of a stud longitudinal section of a second adjacent said unit. Typically, the first and second side planks being adapted to stack over a subjacent unit.

According to another aspect of the present invention there is provided a method of constructing a wall composed of prefabricated stackable wall units, the method comprising the steps of: mounting a first of said units on a sole plate and securing said stud longitudinal section thereof onto the sole plate using securing members and bonding therebetween; and assembling a plurality of said units on top of one another in a stack with securing each said stud longitudinal section to respective said stud longitudinal section of a subjacent said unit using said securing members and bonding therebetween.

Alternatively, the method could comprise the steps of: assembling a plurality of said units on top of one another in a stack with securing each said stud longitudinal section to respective said stud longitudinal section of a subjacent said unit using said securing members and bonding therebetween; mounting the units on a sole plate; and securing the units together and to the sole plate using securing members to longitudinally clamp registered said stud longitudinal sections to each adjacent ones and to the sole plate.

In one embodiment, the through openings slidably receive respective said stud longitudinal section therethrough.

Each wooden plank comprises a plurality of individual planks and such individual planks may conveniently be formed with a tongue and groove interlocking arrangement along respective longitudinal edges thereof.

Moreover, each wooden plank may advantageously be provided with a recess on the top and the bottom thereof for accommodating other building elements such as a sill or sole plate at the bottom or a lintel or top plate at the top.

Each wooden plank is provided at its ends with a recess for receiving part of a wall stud, typically half the width of the stud whereby wooden planks sitting end to end can accommodate and embrace the complete stud to its full dimension.

The stackable unit of the present invention may advantageously be provided with a plurality of planks in the form of logs and successive planks are disposed in such manner as to ensure that the heartwood in each is offset from the heartwood of an adjacent plank thereby to reduce the risk of warping or twisting with age.

According to another aspect of the present invention there is provided a method of constructing a wall composed of prefabricated stackable wall units, the method comprising the steps of erecting a wood frame including vertical studs upstanding from a sill or sole plate, prefabricating stackable units for wall construction of the kind defined by the first aspect of the invention, feeding such units over the studs thereby to accommodate the studs within the through openings formed in the units, and bonding adjacent units together to produce a unitary wall structure around the studs.

In an alternative method the prefabricated stackable units for wall construction are assembled one on top of another with suitable bonding therebetween and mounted on a sill or sole plate, and vertical studs are then inserted into the openings and affixed.

Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, wherein:

FIG. 1 is a top perspective view of an embodiment of a unit for wall construction in accordance with the present invention showing units in the process of being stacked on a stud structure to form a wall construction;

FIG. 2 is an enlarged perspective view of one embodiment of FIG. 1 without studs;

FIG. 2 a is a view similar to FIG. 2, showing another embodiment of the unit with structural stud longitudinal sections permanently secured thereto;

FIG. 2 b is a view similar to FIG. 2 a, showing another embodiment with stud sections having through hole extending therethrough;

FIG. 3 is a left section view of the embodiment taken along line 3-3 of FIG. 2; and

FIG. 3 a is a view similar to FIG. 3, showing two units of the embodiment of FIG. 2 a secured to each other via screws;

FIG. 3 b is a view similar to FIG. 3 a, partially broken, showing a plurality units of the embodiment of FIG. 2 b secured to each other via a screw-nut fastener;

FIG. 4 is a simplified top view of the embodiment of FIG. 1 showing partially two units without studs; and

FIG. 4 a is a view similar to FIG. 4, showing the insulating core spacing the stud from the wooden sides.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the annexed drawings the preferred embodiments of the present invention will be herein described for indicative purpose and by no means as of limitation.

Referring to FIG. 1, there is shown an embodiment of a wall construction unit 10 in accordance with the present invention. The preferably rectangular and generally longitudinal unit 10 comprises mainly a pair of wooden planks, typically engineered wooden planks (EWP), generally flat timber, assembled side planks 20, 22 or the like sandwiching a heat insulating core 50 or layer made of urethane, polyurethane, foamable plastic polymer or the like. The height H of each wall construction unit 10 is typically of approximately twelve (12) inches or one (1) foot, whilst the length is generally of a multiple of sixteen (16) or twenty-four (24) inches, or typically of up to approximately height (8) or twelve (12) feet. The width of each assembled plank 20, 22 is of approximately one (1) inch whilst the width W of the insulating core 50 is of about 3.5 inches to be used conveniently with notional two-by-four (2×4) studs 14 as it will be clearly explained hereinafter. Alternatively, the width W of the insulating core could be of 5.5 inches to be used conveniently with notional two-by-six (2×6) studs.

In territories such as Canada and most States of the United States, construction building codes require a (wooden) wall frame structure to respect certain standards for load-bearing requirements. Notional two-by-four studs 14 can be used with respect to these above-mentioned standards with certain criteria. One of those criteria is the generally horizontal spacing S between the two-by-four or vertical structural studs 14. In FIG. 1, the spacing S is understood to respect those construction building codes and are generally of, for example, twelve (12) or sixteen (16) inches.

As shown in FIGS. 2 and/or 3, each of the EWP or assembled side plank 20, 22 is preferably manufactured by a series of wooden planks 24. Generally vertically, one or a series of intermediate upper grooves 26 are carved on the upper part of each wooden plank 24 to fit or nest with one or a series of intermediate lower tongues 28 carved on the lower part of also each wooden plank 24, except for the ends of the wooden planks 24 forming the ends of the assembled plank 20, 22. Furthermore, each successive wooden plank 24 typically provides for a different grain orientation as indicated by the numeral 30. As one skilled in the art will understand, any piece of cut wood works over time, or, expressed differently, grain orientation affects the straightness or alignment of the wooden plank 24, and thereby of the assembled planks 20, 22 over time. A spiral distortion along the grain creates warping or twisting with ageing of the wood, and this towards the heartwood, represented by the numeral 32. The heartwood 32 of each consecutive wooden plank 24, or the position on the wooden plank 24 where the heartwood would be, is therefore preferably positioned alternatively on the left and then on the right from an approximate vertical reference or axial line L (shown in FIG. 3). The assembled plank 20, 22 is thereby prevented from a strong natural warping tendency towards either side.

Generally vertically, an upper groove 34 is carved on the upper end of the assembled plank 20, 22 to fit or nest with a lower tongue 36 carved on the lower end of another of the same assembled plank 20, 22. Also generally vertically, the amount of insulating core 50 in each unit 10 is such that if two units 10 are positioned one above another, or stacked, there is infinitesimal spacing (not shown) between the two insulating core 50 sections, except for those destined to be lowermost and uppermost insulating core sections 50 of the wall to be constructed. Understandingly, such design of the height H of the insulating core 50 offers the wall to be constructed a thermal insulation across its entire vertical height. As shown in FIG. 1 for a lowermost unit 10 example, the numeral 52 represents a longitudinal void or recess of insulating material adjacent the insulating core 50 for the section of the lowermost (or uppermost) wall construction unit 10 destined to be mounted adjacent a bottom plate 16 (or a top plate, header or lintel not shown), as will be explained further below.

In the longitudinal direction and as shown in the FIGS. 1 and 2 and more specifically in FIG. 4, at each longitudinal end of the unit 10, a recess 54 is left between the insulating core 50 and the adjacent assembled planks 20, 22. The thickness T of the recess 54 is preferably of about half the thickness 2T of the generally vertical component used for structural load-bearing walls, i.e. generally two-by-four studs 14, or three-quarter of an inch (0.75 inch). A void 56 or through opening also of thickness 2T is made in the unit 10 preferably at each equal interval of spacing S. The width W of the void 56 is preferably the same as the width of the insulating core 50. The studs 14 are preferably insulated studs 14 so as to offer thermal insulation across the entire length of the wall to be constructed. Alternatively and in the event wherein the studs 14 to be used are not insulated, the insulating core 50 of the unit 10 could have a larger width (as shown in FIG. 4 a) than the width W of the void 56 with two opposed insulating bands 51 spacing the studs 14 from the corresponding plank 20, 22, each insulating band being adjacent the void 56 and one of the assembled planks 20 or 22 so as also to offer thermal insulation across the entire length (and height) of the wall to be constructed.

The manufacturing operation of the unit 10 is generally and advantageously performed at another location than where the wall is to be constructed. Assembling the wooden planks 24 to form the assembled plank 20, 22 may leave infinitely small openings (not shown) between said wooden planks 24. The insulating material used for the insulating core 50 has such properties that it infiltrates such openings if they are present to ensure an airtight unit 10. In the event wherein some insulating material exits on the exterior surface of the assembled plank 20, 22, shaving or cleaning said insulating material is performed easily. Advantageously, the outer grooves 38 and/or exterior finishing of the assembled planks 20, 22 of the wall construction unit 10 are generally machined if desired during the same or in a subsequent manufacturing step. Preferably, a series of units 10 is brought to the wall construction site once each unit 10 has been completely assembled.

Generally, the structural load-bearing studs 14 for wall construction are mounted vertically on the generally horizontal bottom plate 16. A joining set retarding and expanding epoxy substance, glue, adhesive, resin, foam or the like (not shown) is layered on the upper part of the bottom or sole plate 16. The first wall construction unit 10 comprising the lowermost void 52 is positioned above the structural studs 14 with the voids 56 and recesses 54 vertically aligned with the studs 14. The unit 10 is then lowered down towards the bottom plate 16 as per the general direction indicated by arrows A shown in FIG. 1. A coating of epoxy substance is then layered on the upper part of the installed unit 10 and another unit 10 is positioned above the structural studs 14 with again the voids 56 and recesses 54 vertically aligned with the studs 14, and then again the uninstalled unit 10 is lowered down for stacking on and above the initially installed unit 10, and so on.

Once the wall is assembled as previously described, the set retarding and expanding epoxy has generally the effect of completely filling and sealing the voids and minimal openings (not shown) between the stacked units 10, and between the unit 10 and the bottom plate 16 or top plate, header or lintel. It may be necessary to shave or clean the dried epoxy that would be apparent from the exterior of the wall. An appropriate epoxy retarding time is approximately between 10 and 30 minutes. Obviously, doors and windows (not shown) are usually present in this type of construction. Since said doors and windows are usually positioned at standard spacing intervals, to follow the appropriate spacing for the structural studs 14, the assembly of the units 10 is not adversely affected apart from requiring an appropriate shortening or cutting in some instances, which is standard in the construction industry and not adversely time-consuming. Finally, this example is presented with the structural studs 14 present before the units 10 are stacked one onto the other, but the operations could be reversed, with the studs inserted once the units are positioned stacked onto one another, without departing from the scope of the present invention.

As shown in FIG. 2 a, in another embodiment of the present invention, each unit 10′ has its voids 56′ filled with stud longitudinal sections 14′ permanently secured to the unit 10′ via bonding or the like when inserted thereinto. Each stud longitudinal section 14′ is adapted to structurally connect to at least one stud longitudinal section 14′ of an adjacent unit 10′ via a securing member 60, typically a screw 60 a (see FIG. 3 a) that screwably extends through the stud section 14′ and is partially screwable into the stud section 14′ of a subjacent unit 10′, to form the self-supporting wall structure and have transversal structural loads, typically vertical, transmitted therethrough. Typically, each stud section 14′ is in abutting engagement with the subjacent stud section 14′ or the load support. With this type of securing member 60 a, the lower unit 10′ is first secured to the sole plate 16 and then subsequent units 10′ are stacked over and secured to the subjacent one, with all the stud sections 14′ forming the structural load path of the wall structure.

Alternatively, as shown in FIGS. 2 b and 3 b, each stud section 14′ has a through hole 62 extending longitudinally therealong for slidably receiving a screw-nut fastener 60 b or the like therethrough for connection with the other stud section 14′ in register therewith.

The screw-nut fastener 60 b clamps all the corresponding stud sections in abutting engagement with each other and to the subjacent sole plate 16 or the like and typically a corresponding top plate (not shown). The screw-nut fastener 60 b typically includes an elongate rod 64 having a threaded free end that screwably receives a nut 66 and washer 68. The head 70 of the rod 64, or a hidden nut (not shown), is typically locked to the lower plate 16 (see FIG. 3 b).

With this securing member 60 b, all units 10′ are assembled over each other before they are secured to each other ant to the lower plate 16 and typically the upper plate (not shown) with all stud sections 14′ abutting adjacent ones to form the structural load path of the wall structure.

As schematically shown in dotted lines in FIG. 3 b, each stud section 14′ could have a protrusion member 80, such as a tongue or the like, extending longitudinally outwardly from a first end thereof and a cavity member 82, such as a groove or the like, extending longitudinally inwardly into an opposed second end thereof. The protrusion member 80 is adapted to engage a corresponding cavity member 82 of an adjacent stud section 14′ as an additional securing means as well as a longitudinal guiding alignment means between two adjacent units 10′ when being assembled to one another.

Although the present invention has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed. 

1. A stackable unit for wall construction for cooperation with wall stud members forming a self-supporting wall structure, the unit comprising: first and second opposed elongate side wooden planks secured to one another with an insulating layer bonded thereto, the insulating layer having a plurality of through openings spaced from one another and extending transversely therethrough for receiving a longitudinal section of respective said stud member.
 2. A unit according to claim 1 wherein respective said stud longitudinal section is permanently secured to the unit when inserted into corresponding said through opening, each said stud longitudinal section being adapted to structurally connect to at least one corresponding said stud longitudinal section of an adjacent said unit via a securing member for forming the self-supporting wall structure and having structural loads transmitted therethrough.
 3. A unit according to claim 2 wherein each said stud longitudinal section is adapted to be in abutting engagement with and securable to at least one corresponding said stud longitudinal section of an adjacent said unit.
 4. A unit according to claim 3 wherein each said stud longitudinal section has a through hole extending longitudinally therealong for slidably receiving the securing member therethrough for connection with said at least one corresponding said stud longitudinal section of an adjacent said unit.
 5. A unit according to claim 4 wherein each said securing member forces corresponding said stud longitudinal section to be in abutting engagement with said at least one corresponding said stud longitudinal section of an adjacent said unit.
 6. A unit according to claim 5 wherein the securing member is a screw-nut fastener for clamping corresponding said stud longitudinal section in abutting engagement with said at least one corresponding said stud longitudinal section of an adjacent said unit.
 7. A unit according to claim 3 wherein each said securing member is a screw screwably extending through corresponding said stud longitudinal section and screwing into said at least one corresponding said stud longitudinal section of an adjacent said unit to be in secured abutting engagement therewith.
 8. A unit according to claim 3 wherein each said stud longitudinal section has a protrusion member extending longitudinally outwardly from a first end thereof and a cavity member extending longitudinally inwardly into an opposed second end thereof, said protrusion member being adapted to engage corresponding said cavity member of a stud longitudinal section of a first adjacent said unit, and said cavity member being adapted to receive corresponding said protrusion member of a stud longitudinal section of a second adjacent said unit.
 9. A unit according to claim 1 wherein said through openings slidably receive respective said stud longitudinal section therethrough.
 10. A unit according to claim 9 wherein each wooden plank is provided at its ends with recess means adapted to receive a part of a stud whereby adjacent units sitting end to end accommodate and embrace the stud to its full dimension.
 11. A unit according to claim 1 wherein the first and second planks are engineered side wooden planks.
 12. A unit according to claim 11 wherein each wooden plank comprises a plurality of individual planks formed with a tongue and groove interlocking jointing arrangement along respective longitudinal edges thereof.
 13. A unit according to claim 12 wherein each wooden plank is provided with recess means on the top and on the bottom each being adapted in use to accommodate another building element.
 14. A unit according to claim 12 wherein the individual planks are of log form and successive planks are disposed with the heartwood in one plank offset with regard to the heartwood of an adjacent plank.
 15. A unit according to claim 1 wherein said through openings are spaced from at least one of the first and second planks.
 16. A unit according to claim 15 wherein said through openings are spaced from the first and second planks.
 17. A unit according to claim 1 wherein said through openings extend from the first plank to the second plank so as to divide the insulating layer in a plurality of spaced longitudinal layer sections.
 18. A unit according to claim 1 wherein the through openings are generally equally spaced apart along the unit.
 19. A method of constructing a wall composed of stackable wall units prefabricated in accordance with claim 2, the method comprising the steps of: mounting a first of said units on a sole plate and securing said stud longitudinal section thereof onto the sole plate using securing members and bonding therebetween; and assembling a plurality of said units on top of one another in a stack with securing each said stud longitudinal section to respective said stud longitudinal section of a subjacent said unit using said securing members and bonding therebetween.
 20. A method of constructing a wall composed of stackable wall units prefabricated in accordance with claim 2, the method comprising the steps of: assembling a plurality of said units on top of one another in a stack with securing each said stud longitudinal section to respective said stud longitudinal section of a subjacent said unit using said securing members and bonding therebetween; mounting the units on a sole plate; and securing the units together and to the sole plate using securing members to longitudinally clamp registered said stud longitudinal sections to each adjacent ones and to the sole plate.
 21. A method of constructing a wall composed of prefabricated stackable wall units, the method comprising the steps of: erecting a wood frame including vertical studs upstanding from a sole plate, prefabricating a plurality of stackable wall units in accordance with claim 9; feeding the units over the studs thereby to accommodate the studs within the through openings formed in the units; and bonding together adjacent units to produce a unitary wall structure around the studs.
 22. A method of constructing a wall composed of stackable wall units prefabricated in accordance with claim 9, the method comprising the steps of: assembling a plurality of said units on top of one another in a stack with bonding therebetween; mounting the units on a sole plate; and inserting vertical studs into the openings for fixture to the sole plate. 